Air plug for use in the plastic wrapping of bales of hay to produce and store silage

ABSTRACT

An air plug for use in association with the plastic wrapping of bales of hay to produce and store silage. The plastic wrapped bales form continuous tubes and have a cross section of at least two substantially rectangular bales stacked in vertical alignment. The air plug is a substantially triangular shaped wedge having two matching concave sides and a third convex side for insertion at the perimeter intersection of two adjacent bales, where the concave sides of the wedge engage the hay and the convex side engages the plastic. The plastic wrapping holds the plug in engagement with the hay, preventing the passage of air downstream along the length of the tube upon opening of one end of the tube.

BACKGROUND OF THE INVENTION This application claims priority from U.S. Provisional Patent Application 60/242,059, filed Oct. 23, 2000. FIELD OF THE INVENTION

[0001] The present invention relates to an air plug for use in association with the plastic wrapping of bales of hay to produce and store silage. More specifically, the present invention relates to an air plug for use in association with the plastic wrapping of rectangular or square bales of hay to produce and store silage.

PRIOR ART

[0002] Forage crops such as alfalfa, clover and perennial grasses are typically used as feed for livestock. If exposed to air after harvesting, the crops will inevitably rot or decay rendering them unusable as feed. To preserve the crop material it is transformed into silage. Silage is capable of being stored for extended periods of time, for use as feed during winter months or other periods when livestock are not able to feed in the open. Silage is produced by means of an anaerobic fermentation process. Furthermore, the anaerobic conditions must be maintained in order to prevent the silage from spoiling.

[0003] Silage may be produced, for example, by means of storing the harvested crop material in an airtight silo. Within the silo, the anaerobic fermentation process naturally occurs. The silage is stored in the silo until needed by the farmer. Silos, however, are expensive to build and maintain. For that reason, their use is generally limited to the production of silage on a large scale.

[0004] Small-scale silage production can be achieved by means of wrapping the harvested crop material within an airtight sealed plastic covering. This method of silage production is particularly useful for smaller farming operations. Typically, the crop material is baled prior to wrapping. By wrapping the crop material in plastic, an anaerobic environment is created inside of the plastic wrapping in which the fermentation process can occur. The silage is stored within the plastic wrapping material until needed by the farmer. The process of producing silage by means of wrapping the crop material in plastic is hereinafter briefly described.

[0005] After being cut, the crop material is collected and formed into bales. This allows the crop material to be stored, handled and transported more efficiently. The bales are formed using a baler, a machine that tightly wraps the crop material in twine. Bales are typically circular, rectangular, or square in shape. Various types of balers are known in the art. Furthermore, different types of balers produce different shapes and sizes of bales.

[0006] The present invention relates to the plastic wrapping of rectangular or square bales. In practice, the bales are not perfectly rectangular or square in cross-section. The edges and corners of the bales are rounded due to the tight winding of the twine that holds the shape of the bale.

[0007] The plastic wrapping process begins by lifting the bale onto a bale-wrapping machine. Various bale-wrapping machines for use in the plastic wrapping of bales, and in particular the plastic wrapping of rectangular or square shaped bales, are known in the art. Typically, rectangular and square bales are stacked in alignment prior to wrapping. Stacks of between two and four bales are most common. The plastic material is then circumferentially wrapped around the stacked bales. As the stacked bales are fed through the bale-wrapping machine, the plastic is wrapped along the entire length of the bales. Additional stacked bales are sequentially fed into the bale-wrapping machine so as to produce a row of bales continuously wrapped in plastic. As the wrapped bales exit the wrapping machine, they are deposited onto the ground where they are stored until needed. The length and positioning of the continuously wrapped row of bales may be varied according to the specific needs of the farmer.

[0008] A biodegradable plastic film is used to wrap the bales. The plastic material is approximately 1 mm thick and is wrapped around the bales several times to ensure that at least 6 mm of plastic surrounds the bales. Exposure to the sun degrades the plastic over time and the additional thickness of plastic protects the silage from exposure to the air during storage.

[0009] The fermentation process, which produces the silage, occurs naturally within the anaerobic environment created inside of the plastic wrapping. The anaerobic environment created inside of the plastic wrapping further prevents the silage from spoiling during storage. When needed for use as feed, the farmer opens one end of the plastic wrapping and selectively and sequentially removes the silage from the plastic wrapping. This is a problem as air may thereby enter inside of the plastic wrapping and expose the silage to air.

[0010] With stacked rectangular or square shaped bales, air entering inside of the plastic wrapping through the opened end is a significant problem. Air tunnels are inherently created within the plastic wrapping due to the fact that the edges of the bales are not 90.degrees. When rectangular or square bales are stacked one on top of the other in alignment, a substantially V-shaped recess is created surrounding the area at which the bales come into contact. Once wrapped in plastic, the plastic material encloses the V-shaped recess creating a tunnel. The tunnel, therefore, is defined on one side by the lower rounded edge of the top bale in the stack, on another side by the upper rounded edge of the bottom bale in the stack, and on the third side by the plastic film.

[0011] Where a row of stacked rectangular or square bales is continuously wrapped in plastic, a tunnel is defined along the entire length of the row of bales. It should be noted that where two bales comprise a stack, two tunnels are created, one on each side. If the stack is comprised of three bales, four tunnels are created, two on each side. The tunnels created during the plastic wrapping process permit air to travel deep inside of the plastic wrapping. As a result, the anaerobic environment within the plastic wrapping is compromised leading to rotting and spoilage of the silage contained within.

BRIEF SUMMARY OF THE INVENTION

[0012] The present invention is intended to overcome the disadvantages associated with the prior art method of wrapping rectangular or square bales in plastic to produce and store silage. In particular, the present invention is intended to overcome the disadvantages associated with the prior art method of wrapping stacked rectangular or square bales in plastic to produce and store silage.

[0013] The object of the present invention is to provide a device for use in association with the plastic wrapping of rectangular or square bales stacked in alignment, which prevents air from compromising the anaerobic environment within the plastic wrapping. In particular, the object of the present invention is to provide a device which prevents air from travelling though the air tunnels created when a row of stacked rectangular or square bales is continually wrapped in plastic.

[0014] The objects of the present invention are achieved by means of an air plug which acts as an air barrier. It prevents air from entering into and traveling through the tunnels created when a row of stacked rectangular or square bales is continually wrapped in plastic. The objects of the present invention are further achieved by means of positioning a plurality of air plugs at pre-determined intervals along the length of the tunnels, such that as bales are sequentially removed from the open end of the plastic wrapping the anaerobic environment therewithin is maintained.

[0015] By positioning a plurality of air plugs at pre-determined intervals within each tunnel, the amount of silage material exposed to air at any point in time is minimized. Air entering through the open end of the plastic wrapping is able to travel only a limited distance within the tunnel before coming into contact with an air plug. The air plug stops air from penetrating any further into the tunnel. Spoilage is thereby minimized, since the silage material that is exposed to air is typically used before any significant spoilage can occur. As the silage material and air plugs are sequentially removed, an anaerobic environment within the plastic wrapping is continually maintained. The intervals at which the air plugs are positioned may be determined according to the particular feeding schedule of the farmer.

BRIEF DESCRIPTION OF THE DRAWINGS

[0016] For a better understanding of the present invention, the invention is described with reference to the accompanying drawings, wherein like reference numerals are used to indicate like parts in the various views.

[0017]FIG. 1 is one perspective view of the present invention.

[0018]FIG. 2 is second perspective view of the present invention from a different angle.

[0019]FIG. 3 is a perspective view illustrating the air tunnels created when two rectangular bales are stacked in alignment.

[0020]FIG. 4 is a schematic diagram illustrating the air plug in relation to two rectangular bales stacked in alignment.

[0021]FIG. 5 is schematic diagram showing two stacked rectangular bales wrapped in plastic with two air plugs in position.

[0022]FIG. 6 is a schematic diagram of a row of stacked rectangular bales with a plurality of air plugs positioned at regular intervals along the row (plastic wrapping material not shown).

PREFERRED EMBODIMENT

[0023] The preferred embodiment of the air plug (1) is shown in FIGS. 1 and 2. It has a uniform substantially triangular cross-section and a uniform thickness (t). The air plug has five surfaces, namely, a convex base (2), two identical concave sides (3 a and 3 b) and two identical faces (5 a and 5 b). The concave sides intersect to present a peak (7). The specific dimensions of the air plug may be suitably adapted to be used in association with bales of different sizes.

[0024] The air plug (1) is preferably made of a light, resilient polystyrene plastic. Since polystyrene plastic tends to chip and fray, in particular at the corners and edges, the air plug is preferably coated with a plastic substance (not shown in Figures) to make it more durable. The air plug is preferably solid throughout and of one-piece construction.

[0025] Referring still to FIGS. 1 and 2, the identical faces (5 a and 5 b) of the air plug (1) are triangular-like in shape. The convex base (2) of the air plug is curved gently and outwardly, and appears convex when the air plug is viewed in plan view.

[0026] The concave sides of the plug (3 a and 3 b) are curved gently and inwardly, and appear concave when the air plug is viewed in plan view.

[0027] As described above, the process of wrapping rectangular or square bales in plastic begins by lifting and placing the bales onto a bale-wrapping machine. Referring to FIG. 3, prior to wrapping the bales are typically stacked in alignment. Stacks of between two and four bales are most common. The stacked bales are then fed into the bale-wrapping machine, which wraps the bales in plastic, forming a continuous tube of hay.

[0028]FIG. 3 shows two rectangular bales stacked one on top of the other. The upper bale (10 a) is positioned on top of the lower bale (10 b) in alignment therewith. The corners and edges of the rectangular bales are rounded (as shown, for example, at 11) due to the tight winding of the twine that holds the shape of the bale. When the bales are stacked in the manner described, a substantially V-shaped recess (12 a and 12 b) is defined by the curved edges of the bales surrounding the area where the two bales come into contact. When the bales are subsequently wrapped in plastic (not shown in Figure), a substantially triangular shaped tunnel is formed (as shown by cross-hatching). The tunnel is defined on one side by the lower rounded edge of the top bale in the stack, on the other side by the upper rounded edge of the bottom bale in the stack, and on the third side by the plastic film.

[0029] Referring to generally to FIGS. 1 and 2, and in particular to FIG. 4, the shape of the air plug (1) is complementary to the shape of the recess created when the bales are stacked in alignment. The air plug is thus suitably adapted to fit into the recess (as shown, for example, at 12 a and 12 b).

[0030] The air plug (1) is positioned such that one face (5 a) is flush with the front face of each of the bales comprising the stack (10 a and 10 b). The plug is inserted at the perimeter intersection of the width of two adjacent bales. It should be noted that as the faces and concave sides of the air plug are identical, either face may comprise the front face. The front face for the purposes of this specification is that face which is to be projected towards the open end of the plastic wrapping. The peak (7) of the air plug fits into the recess such that one concave side (3 a) tends to engage the lower rounded edge of the top bale (10 a) while the other concave side (3 b) tends to engage the upper rounded edge of the bottom bale (10 b). When the concave sides are in engagement with the bales, air is prevented from passing therebetween.

[0031] Referring to FIG. 5, once in position, the air plug (1) is held securely in place by the plastic film (20), which is wrapped around the bales. A bale-wrapping machine such as, for example, the Reeves In-Line Bale-Wrapper™, is used to wrap the plastic film around the bales. The air plug is positioned manually during the plastic wrapping of the bales. As the plastic film (20) is wrapped tightly around the bales, a tight seal is created between the plastic film and the convex base (2), which prevents air from passing therebetween. As well, the pressure exerted by the plastic wrapping material against convex base (2) forces the concave sides (3 a and 3 b) into firm engagement against the bales. This further helps prevent air from passing between the concave sides and the bales and the air tunnel now sealed.

[0032]FIG. 6 shows a row of stacked bales. A row of stacked bales continuously wrapped in plastic is created by means of sequentially feeding stacked bales into the bale-wrapping machine (plastic film not shown). The number of bales comprising the row may be varied according to storage and feeding needs of the farmer.

[0033] Referring still to FIG. 6, a plurality of air plugs (1) is shown positioned at predetermined intervals along the entire length of the row. Each air plug is positioned according to the method set out above. The front face of each air plug is positioned flush with the front face of each of the bales it engages. Moreover, two air plugs, one on each side of the stack, are placed at corresponding intervals along the row.

[0034] The interval at which the air plugs are positioned may be planned out in advance according to the specific feeding requirements of the farmer. For example, a farmer who requires one bale per day to feed his livestock correspondingly needs ten bales for every ten-day cycle. This farmer should position air plugs at five-bale intervals along the entire length of the row (as shown in FIG. 6).

[0035] From the foregoing, it will be seen that this invention is one well adapted to attain all the ends and objects hereinabove set forth together with other advantages which are obvious and which are inherent to the structure.

[0036] It will be understood that certain features and sub-combinations are of utility and may be employed without reference to other features and sub-combinations.

[0037] Since many possible embodiments may be made of the invention without departing from the scope of the thereof, it is to be understood that all matter herein set forth or shown in the accompanying drawings is to be interpreted as illustrative and not in a limiting sense. 

1. An air plug for use in the plastic wrapping of a tube of hay consisting in cross section of at least two vertically stacked bales of hay, said wrapped tube having a length and an open end, said plug comprising a substantially triangular shaped wedge having a thickness, two matching concave sides and a third convex side, for insertion at the perimeter intersection of two adjacent bales, wherein the concave sides of said wedge are to engage said adjacent bales and wherein said convex side is to be engaged by said plastic.
 2. The invention as claimed in claim 1, wherein said bales of hay are substantially square-like in cross-section.
 3. The invention as claimed in claim 1 or 2, wherein said thickness of said wedge is uniform.
 4. The invention as claimed in claim 3, wherein said wedge is made from a plastic material.
 5. The invention as claimed in claim I or 4, wherein said plastic wrapping is continuous along said length of said tube and wherein each said wedge is positioned at discrete intervals along said length of said tube to prevent the downstream passage of air along said length of said tube from an open end thereof.
 6. A method for preserving hay by means of using the air plug of claim 5, wherein a plurality of said air plugs are positioned at discrete intervals along the length of said tube of hay and wherein said tube and said wedges are continuously wrapped in a plastic material for preserving said hay. 